Heaset repair

Discussion in 'Technical Corner' started by Daniel L, May 23, 2019.

  1. Daniel L

    Daniel L Pre-takeoff checklist

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    With the purchase of Ms. Thang came inheritence of a variety of aviation related gear. One of which is a pile of old headsets that were discarded for one defect or another. The best of this example is a Flightcom Blackhawk Model 5DX.

    I flew one day with my A&P who wore it and the only defect I could detect was intermittent output while speaking on the open intercom. When he spoke with the controllers it was fine. So it seems the limitation is ilimited to intercom speak. Once the mic button is pressed the defect is gone.

    I'd like to take a stab at repairing this set and make it a back-seat pair. Opinions? Worth the effort? If it yields nothing I may a learn a bit about these headsets. If it yields a repaired headset then great; either way I learn something.

    Otherwise the pair seems to be in great shape and it would be a shame to let them go to waste.

    Thanks,

    D 20190523_214709.jpg 20190523_214813.jpg

    Sent from my SM-T350 using Tapatalk
     
  2. dmspilot

    dmspilot En-Route

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    Might not be anything wrong with it, sounds like the mic is just not breaking the intercom squelch. Talk louder and put the mic closer to your mouth.
     
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  3. Huckster79

    Huckster79 Line Up and Wait

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    I have a set that just went dead one day, some rainy day in just gunna crack or open- figure I can’t break it worse... might be a simple solar connection broke... but I figure if it’s already broke why not give it a shot?
     
  4. Ghery

    Ghery Final Approach

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    Go for it. The next time I have to fix one of my Softcomm C-90s I'll probably have to mess with it myself.
     
  5. 455 Bravo Uniform

    455 Bravo Uniform En-Route PoA Supporter

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    Is there a gain potentiometer under those mic screws that you can access? Maybe worth opening up to check and turn it 1/8 at a time until you get what you need.

    Or maybe intercom squelch is set too high?
     
  6. FlySince9

    FlySince9 En-Route

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    Depending on the manufacturer, could be a mistake... I know D/C will fix almost anything for little or no charge. If you crack it open all that goes out the door... Contact the manufacturer first. You might be surprised...
     
  7. Ravioli

    Ravioli Final Approach

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    Does it work correctly plugged in to any of the other jacks?
     
  8. Huckster79

    Huckster79 Line Up and Wait

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    Oh this one is a backseat cheapy I bought used from eBay 15 years ago...
     
  9. FlySince9

    FlySince9 En-Route

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    Go for it, then! I love pulling stuff apart too...
     
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  10. gkainz

    gkainz Final Approach

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    especially when "What's the worst that could happen? It's already broke!"
     
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  11. Ravioli

    Ravioli Final Approach

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    But is it ACTUALLY broken or does it work in the other seat positions?
     
  12. Zeldman

    Zeldman Touchdown! Greaser!

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    I have replaced a speaker, cord and a microphone on my ANR headset. These things aren't rocket surgery....

    (and I have won a couple Darwin awards....)
     
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  13. Daniel L

    Daniel L Pre-takeoff checklist

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    it acts the same no matter where i plug it in or squelch setting. i gave him a set i know works and it worked perfectly. im going to open the mic and see if it can be adjusted but first will call the manufacturer.

    Sent from my SM-J327P using Tapatalk
     
  14. Huckster79

    Huckster79 Line Up and Wait

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    This is much of my life’s philosophy I’ve fixed all sorts of crap I didn’t know a thing about... just use a critical eye n go slow and/or the google...
     
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  15. Daniel L

    Daniel L Pre-takeoff checklist

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    It turns out this set is really really really basic.

    Other than a cheap mic and a cheap speaker and some foam, there's nothing more to it. You can still buy one new for $189 which, going by the build quality, is way overpriced.

    I tested it today, the right speaker doesn't even work. I can't find a part number for it to buy as a component so I may just junk it.

    The manufacturer only sells pads and mic shields for the thing. Going to waste basket. I will be searching now for a good used set on ebay or craigslist.

    Sent from my SM-T350 using Tapatalk
     
  16. asicer

    asicer En-Route

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    I believe the ANR kit comes with speakers.

    http://headsetsinc.com/ANR_kits.html

    Also, you said you got a pile of headsets. Any way to mix and match parts Frankenstein style?
     
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  17. dmspilot

    dmspilot En-Route

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    That's what happens when you have it set to Stereo and use it with a mono audio panel.
     
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  18. Daniel L

    Daniel L Pre-takeoff checklist

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    Yeah I thought the same thing but it acts that way even in mono mode. I do have a mono audio panel.

    Sent from my SM-T350 using Tapatalk
     
  19. Daniel L

    Daniel L Pre-takeoff checklist

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    Funny you mention that. I brought the headsets home thinking of doing just that since they're all the same brand.

    Some seem to have been decommissioned due to lack of an ear pad. Pictures attached. I was going to clean them and test. If they work but just need new pads, I may just use them instead. 20190525_230106.jpg 20190525_230113.jpg

    Sent from my SM-T350 using Tapatalk
     
  20. Daniel L

    Daniel L Pre-takeoff checklist

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    I believe the problem has been identified. I opened up the volume side on the headset and the first thing I noticed was a wire disconnected from the breadboard. So now I need to figure out which pin to reattach it to. I have a magnifying glass. Maybe the cleanest one is it.

    The headset took some damage because there are plastic bits broken off that began rattling around after I removed the foam. So it could've happened at that time. 20190526_000515.jpg

    Sent from my SM-T350 using Tapatalk
     
  21. Daniel L

    Daniel L Pre-takeoff checklist

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    Once I put the bread board into its position, the loose connector (based on the angle it was bent) naturally fell in place in the third pin. I noticed that it slid in really loosely so I crimped it down a bit. It fit perfectly.

    So I'll be testing it tomorrow.

    Now I have these two cheapies to consider as well.

    Sent from my SM-T350 using Tapatalk
     
  22. dmspilot

    dmspilot En-Route

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    Got it. Thanks for the follow up. Just wanted to make sure you weren't throwing out an innocent headset. If you're patient you can find some surprising deals on eBay.